Evolution of Product Lifecycle Management (PLM) Systems
Product lifecycle management (PLM) refers to the process of managing a product from its initial design conception all the way through its eventual retirement and disposal. As products and manufacturing have become more complex over time, PLM practices have also evolved considerably.
In the early days of manufacturing, PLM needs were very basic and ad-hoc. A product was designed, manufactured, sold and that was the end of product life. There wasn't much thought given to ongoing information management of product, supply chain coordination or analyzing a product's complete lifecycle. There were less frequent changes in the product, far less moving parts in the total product composition and lacks long range planning and allocation of resources.
Over the time products in itself become complex composition of several components, production volumes grew in the industrial age, companies globalised, and billions spent on research and development. It became more important to diligently track product data like design, technical specs, prototypes, and supplier information etc. Basic PLM systems emerged, usually centred around physical file stores and product documentation vaults protecting the intellectual property.
With the rise of computers in the mid-late 20th century, PLM capabilities advanced significantly. Automobile industry has taken the lead in replacing paper trails with digital product data in authoring and sharing more easily across departments. Computer-aided design (CAD), visualization tools, and digital mock-ups accelerated the research and design phase by converting physical drawings to digital drawings.
In the modern age, the idea of PLM transitioned from discrete industries to process industries. As income level grew, so did the appetite of consumers for more products and services. Inlined with it, the process industries like consumer packaged goods, chemical, pharma etc. had to grapple with numerous offerings of products and its formulations, packaging, and regulations.
PLM software has become incredibly sophisticated, with integrated suites covering the full product lifecycle. Solutions exist to optimally manage portfolios, collaborate across the value chain, track requirements, streamline quality processes, and even plan for recycling and disposal. State-of-the-art PLM leverages cloud computing, mobile, analytics, AI and more. The goal is to compress cycle times, facilitate innovation, reduce costs and environmental impacts across the product's life.
While PLM basics haven't changed - to get a product designed, made and sent to market efficiently - the processes and technologies supporting it have evolved tremendously. Simple PLM transformed into today's digital product development environment with rich data, cross-functional collaboration and a focus on sustainable lifecycles.
Phases of product development in process industries:
Product development in process industries depending on a organisation typically consists of several phases over its lifecycle:
Ideas and Concepts
During this stage, concepts are developed and ideas are gathered to target possible product outcomes or requirements in the process sector. Feasibility, scalability, and alignment with customer and industry competitiveness are among the variables that are taken into consideration while exploring and evaluating potential solutions and new products.
Research and development
Before freezing on concepts and product ideas effectively, it's crucial to conduct extensive research. This leads to validating the attainability of product characteristics of proposed ideas. Which will also involve exploring market trends, technological advancements, and consumer preferences.
This phase sustains throughout the lifecycle of a product, even after the launch of the product-one has to incrementally make changes to refine customer experience, product performance, and reliability. Meticulous sampling, lab-level testing and analysis can also help us identify the practical limitations of the idea.
Design and development
The design and development process starts when a workable concept is chosen. Here, multidisciplinary teams of scientists, formulators, seal-out engineers, designers, and experts collaborate to translate the concept into tangible prototypes, while also refining product specifications and features.
Testing and Certification
The product goes through extensive testing during this crucial stage to make sure it satisfies strict quality standards and legal requirements. This comprises third-party certifications and internal testing methods to confirm adherence to industry regulations and safety requirements.
Production and launch
In this stage, the product enters production when testing and certification are successfully completed. Production facilities are built up or reconfigured as needed, and manufacturing processes are optimized for scalability and efficiency. Distribution routes are set up to guarantee wide availability and marketing campaigns are stepped up to raise awareness among prospective clients.
Post-Launch Support
Even after the product is launched, ongoing support is crucial in the process industry. This includes providing technical assistance to customers, by addressing any issues or concerns that arise and gathering feedback for continuous improvement. Sustainable use and disposal of products has to be considered in product design.
Adding to this, post-launch support may involve offering maintenance services, and training programs to ensure optimal performance and customer satisfaction with the product’s lifecycle.
